Reactor

ABSTRACT

The present application provides a reactor for: converting feedstock material into gases; or disassociating or reforming a chemical compound; and/a mixture to its constituent elements; and/to other chemical forms, and; finally a heating device. The reactor comprises a heating device for discharging an ionized gas into the reactor, a feedstock feeder for injecting the feedstock material into the reactor, and a shell forming a chamber that encloses a portion of the heating device and a portion of the feedstock feeder. The application also provides a method for converting hydrocarbon material into synthetic gases. The method comprises: providing the hydrocarbon material to a burner inserted into a reactor, a second step of supplying ionized gases into the reactor, and a third step of subjecting the burner to a flame of the ionized gases such that molecules of the hydrocarbon material are dissociated to forming synthetic gas.

RELATED APPLICATION

This application claims the benefit of and is a continuation ofco-pending U.S. patent application Ser. No. 14/362,320, filed on Jun. 2,2014, entitled “REACTOR,” which is a U.S. national phase applicationunder 35 U.S.C. §371 of International Application Serial No.PCT/SG2012/000450, filed on Nov. 29, 2012, and claims the priority under35 U.S.C. §119 to Singapore Patent Application No. 201108938-0, filed onDec. 2, 2011 and Singapore Patent Application No. 201205660-2, filed onJul. 30, 2012, which are hereby expressly incorporated by reference intheir entirety for all purposes.

FIELD OF THE INVENTION

The present application relates to a reactor. It also relates to methodsof making, installing, assembling, disassembling and using the reactor.

BACKGROUND OF THE INVENTION

Traditional power generation, either in large or small scales, usuallyoccurs in the forms of burning fossil fuels, such as coal, natural gasand petroleum. These methods typically cause environmental pollution.For example, an Internal Combustion Engine using the petroleum normallyreleases particulate matters, nitrogen oxides, carbon dioxide, sulfurmonoxide and sulfur oxides into the air, which are toxic to human andanimals. Although nuclear power plants generate about 13-14% of theworld's electricity at present, many organizations (e.g. Green PeaceInternational) and individuals believe that nuclear power poses threatsto people and environment. Alternative sources, including various formsof renewable energy, generally face the problem of high cost and poorefficiency. Technologies for power generation with high efficiency, lesspollution and low cost are much desired.

SUMMARY OF THE INVENTION

A first aspect of the present invention provides a reactor forconverting or reforming a feedstock material into gases or dissociatingthe feedstock material into its constituent elements/molecules (e.g. gasor powder). The feedstock material includes various types of natural orsynthetic materials from ecosystem or factories. For example, thefeedstock material includes hydrocarbon material of an organic mixturesuch as human waste, manure, forestry products, agricultural products,and other biodegradable materials. The feedstock material also includeshydrocarbon of non-organic types, having hydrogen or carbon, such asplastics, ammonia, water and hydrogen sulfide. The reactor is furtherconfigured to disassociate some chemical waste materials (e.g. hydrogensulfide H₂S) into hydrogen gas (H₂) and sulfide powder (S).

The reactor comprises a heating device for discharging an ionized gas orionized gases into the reactor, a feedstock feeder for injecting thefeedstock material into the reactor, and a shell housing forming achamber that encloses one or more parts of the heating device, and oneor more portion of the feedstock feeder inside the chamber. The heatingdevice can provide an initial source of heat for ignition or burning.Often, the heating device is automatically regulated for operation.

The feedstock material is configured to be disassociated into syntheticgas or particles by flames of the ionized gas. Under a temperature above2,200° C., the feedstock material, either in a mixture or a singlesubstance form, is split into elemental molecules in forming thesynthetic gas, such as carbon monoxide (CO), carbon dioxide (CO₂),hydrogen gas (H₂) and CH (e.g. Methane).

The heating device is configured to be kept electrically neutral fordissociating the feedstock material. In other words, the heating deviceneither passes electric currents between its components for ionizinggases, nor discharges electric currents to surroundings (e.g. ambientgases) such that corrosion of the heating device is avoided orminimized. No parts of the heating device is subjected to high voltageor electric current such that the heating device becomes inert to itsambient, in contrast to electrically charged metal parts surrounded byplasma, which occurs in a plasma torch. Life span of the heating deviceis much extended; whilst the reactor also has low operation cost andrequires less maintenance.

Since the high temperature is generated by the ionized gas(es), noextensive electric field of high voltage is applied inside the reactor.No electrode is exposed to high voltage such that both the heatingdevice and the portion of feedstock feeder (e.g. burner) are not erodedeasily. Hence, components inside reactors, including the heating deviceand the feedstock feeder, can have a prolonged life span for durableoperation with stable performance. Inside the reactor, since thefeedstock material is disassociated under the high temperature in alimited supply of oxygen, the synthetic gas can be discharged out of thereactor for other applications, such as providing fuel to a boiler. Thereactor may produce carbon dioxide gas (CO₂), which is carbon neutral asits carbon source is not from fossil fuels. The synthetic gas offers auseful source of energy, which is environmental friendly. When wastematerial is used as feedstock to the reactor, the waste material iseliminated, which no longer cause pollution to the environment.

The feedstock feeder comprises a burner (i.e. first burner) hermeticallyinserted into the chamber, such that the reactor may be operated at apositive pressure (i.e. internal pressure higher than ambient pressure),a negative pressure (i.e. internal pressure lower than ambient pressure)or an ambient pressure. Alternatively, the burner may be inserted intothe chamber without the hermetic sealing. One or more components of theburner are made of a material for withstanding high temperature (i.e.above 1,000° C. Degree Celsius). The robust material prevents the burnerfrom being destroyed or deformed for durable and long-lasting operation.For example, the burner can be made of a ceramic material, a metal or acomposite material, such as silicon carbide, tungsten, tungsten carbide,tantalum, tantalum carbide, tantalum hafnium carbide, hafnium carbide.

The burner may comprise internal, external or both types of channels forfeeding the feedstock material into the chamber. These channels havepredetermined sizes for feeding the feedstock material into the reactorat predetermined flow rates. For example, the burner can have eightchannels and each of these channels has a diameter of 0.5 mm(millimeters) for feeding the feedstock material at 1.5 liter perminute. The feedstock material can cool down the burner in the progressof feeding through the channels.

The one or more components of the burner may include an electricallyconductive material such that the ionized gas can raise temperature ofthe burner markedly when touching the burner with its ionized flames.For example, the burner can be entirely made of Tungsten material whosemelting temperature is about 3,422° C.

The one or more components of the burner can be placed adjacent to theheating device such that the flames of the ionized gases are configuredto touch the burner for disassociating the feedstock material. Theburner can be elevated to a temperature above 1,000° C. for burners ofsteel material, 2,200° C. for burners of ceramic materials, or 3000° C.for burners of tungsten material such that the feedstock materialpassing through the burner is exposed to the high temperature and may bedisassociated into the synthetic gas. More advantageously, since theburner and the heating device are placed in close proximity, flames ofthe heat device can easily wrap around exterior surfaces of the burnersuch that the burner may be uniformly heated up quickly.

The burner can alternatively comprise an Archimedean screw feeder and afeedstock propeller coupled together for injecting the feedstockmaterial into the reactor. The Archimedean feeder provides an efficientfeeding mechanism for supplying the feedstock material into the reactor.Feeding rates of the Archimedean feeder can easily be regulated byadjusting a rotation speed of a feeding screw of the Archimedean feeder.When required, the feeding screw can be replaced for changing a pitchdistance (channel size) between its neighboring teeth and the depth ofthe teeth. Hence, the Archimedean screw feeder can be adapted to feedthe feedstock material with different particle content/size, watercontent of various viscosities as well as gaseous. The Archimedean screwfeeder may be replaced by other similar means for propelling thefeedstock material, such as a slurry pump.

The Archimedean screw feeder comprises a replaceable feeding screwfitted inside a feeding sleeve for propelling the feedstock materialbetween neighboring teeth of the feeding screw. The feeding sleeve maytightly enclose the replaceable feeding screw such that the feedstockmaterial can be completely blocked from entering the reactor when thereplaceable feeding screw is held standstill. In other words, theArchimedean screw feeder can also operate as a valve for regulating theflow rate of the feedstock material. Alternatively, either the feedingsleeve, or both the feeding sleeve and feeding screw have teeth suchthat the feedstock materials can be propelled by the teeth.

Similarly, one other method is using a tube with inner threads embracedthe burner or another method, the burner has inner or outer or boththreads embraced by inner or and outer tubing. The tube with threads orthe burner with threads turns by a first motor and the feedstockmaterial is fed to the burner. A second motor rotates the burner back &forth (rocks) to prevent over burning if tube with thread is used. It ispossible to use a motor to rock the HHO supply tube and thus the flamerocks and the burner remains still if the tube with thread is used. Ifthe burner has thread, then it will be continuously rotated by a motorand HHO flame can be stationary.

The Archimedean screw feeder and the feedstock propeller may besupported on a wall bracket bearing and a screw bearing respectively forrotating the feeding sleeve, the feeding screw, or both. The bearingspermit relatively easy rotation between the Archimedean screw feeder andthe feeding sleeve.

The shell can comprise or incorporate a heat exchanger that is connectedto a portion of the shell for cooling the shell. The heat exchanger canbe a shell and tube heat exchanger, a plate heat exchanger, a plate andshell heat exchanger, a plate fin heat exchanger, or other types of heatexchangers. In an embodiment, the heat exchanger has fins on an exteriorsurface of the shell such that a refrigerant or coolant flowing over thefins can extract heat away from the shell. The shell is kept at a lowtemperature (e.g. below about 100° C.) for achieving stable operation ofthe reactor.

The reactor may further comprise a slag collector at a bottom side ofthe reactor for collecting and disposing solid waste (e.g. dust/powdercollection). When adopting organic waste mixture as the feedstockmaterial, some elements of the mixture may form a mixture of metaloxides and silicon dioxide. However, the slag can also contain metalsulfides and metal atoms in the elemental form. The slag is dischargedperiodically out of the reactor during a continuous operation of thereactor. The slag can be used as construction material or industrial rawmaterial.

The shell may seal the chamber hermetically such that the reactor isconfigured to operate at negative pressure. Under the negative pressure,since a chamber of the reactor has a lower pressure than its ambient,the ionized gases can easily flow into the reactor without the danger ofcausing backlash to an ionized gas generator (e.g. HHO gas generator).Alternatively, the reactor can be operated positive pressure such thatthe pressure inside the chamber is higher than the ambient pressure ofthe reactor, and the synthetic gas can be easily discharged, collectedor burnt at a vent of the reactor for pressure relief. The shell may beopen to ambient such that the reactor can operate at ambient pressure(e.g. atmospheric pressure).

In a preferred embodiment, the reactor further comprises a regulatorconnect to one or more of the feedstock feeder, the heating device andan exhaust (i.e. an inlet of a gas separator) for controlling moleculardisassociation process in the chamber. The regulator includes one ormore microprocessors that coordinate the feedstock feeder, the heatingdevice and the exhaust automatically. In one embodiment, the regulatoris an industrial computer, which is installed with computer softwareprograms for operating the reactor automatically.

The regulator may be connected to one or more temperature sensors insidethe chamber or on the shell for monitoring an internal temperature ofthe reactor. The temperature sensors check temperatures at variouspositions of the reactor such that the shell can be cooled down, whilstthe feedstock material can be disassociated at the high temperatureconstantly.

The regulator is connected to a feeding valve, a pump or othercontrol/propelling devices on a feeding tube of the feedstock feeder foradjusting flow rate of the feedstock material. The feedstock materialmay have different proportions of organic content and water contentdepending variations of the feedstock material. The flow rate of thefeedstock material is coordinated with the supply of the ionized gas forcontrolling disassociation rates of the feedstock material and theproduction volume of the synthetic gas. The feeding valve may beelectrically controlled, having a non-return valve or both. Thefeedstock feeder may further comprise an electrically controlled pumpfor pressurizing the feedstock material for feeding. The feeding valvemay be replaced by a pump, or other regulating means.

The regulator may be connected to a discharging valve, a vacuum pump, orsuction pump for the exhaust for governing flow rate of the syntheticgas. The exhaust adjusts the output of the synthetic gas such that thesynthetic gas burning rate or storage of the synthetic gas iscoordinated with the dissociation process of the feedstock material. Inshort, all processes of the reactor are brought under the control of theregulator for complete automation.

The present application can provide a gasification device that comprisesthe reactor and an HHO gas generator. The HHO gas generator is connectedto the heating device for supplying the ionized gases. The ionized gasescomprise oxygen gas, hydrogen gas and free ions of oxygen and hydrogenmolecules (O₂, H₂, O⁻², H⁺, HO⁻). In contrast to pure oxygen andhydrogen gases (no electrical charge), the ionized gases can be burnt ata much higher temperature of more than 2,200° C., which is sufficientfor disassociating the hydrocarbon material into the synthetic gas. Inone preferred embodiment, the ionized oxygen and hydrogen gases (i.e.HHO gas or oxyhydrogen gas) is generated by an electrolysis process inwater solution of potassium hydroxide. The potassium hydroxide solutionmay be replaced by water. Electrodes for conducting the electrolysisprocess may be charged with continuous supply of constant voltage (e.g.DC) or pulsating direct current.

The HHO gas generator can further comprise a water tank. The water tankcomprises a liquid orifice for receiving water in liquid or gas form,and a gas orifice for releasing the ionized gas. The water tank isconnected to reactor such that water from the reactor is received by thewater tank for generating the ionized gas, whilst the ionized gas issupplied to the heating device of the reactor. Various parts of thegasification device interact and operate together in a regulated manner.

The HHO gas generator can further comprise a Direct Current (DC) powersupply for supplying an electric current to an anode and a cathode inthe water tank. Outputs (e.g. voltage and current) of the DC powersupply may be connected to the regulator for regulating production rateof the ionized HHO gas (i.e. oxyhydrogen gas). Any of the anode andcathode can be in the form of parallel metal plates dipped or immersedinside the water solution. The water tank may have a water levelindicator or sensor, which is further connected to the regulator forcontrolling water level inside the water tank.

The gasification device can further comprise a pressurized gas loopoptionally having a reactor portion that is connected to the reactor forabsorbing heat from the reactor. The pressurized gas loop contains aworking fluid (i.e. refrigerant) that is configured to be circulatedaround the reactor (e.g. shell) and inside the pressurized gas loop. Theworking fluid includes chlorofluorocarbons, ammonia, sulfur dioxide,carbon dioxide, water and non-halogenated hydrocarbons (e.g. propane).The pressurized gas loop can utilize phase change of the refrigerant forextracting heat from the reactor effectively. The refrigerant inside thepressurized gas loop is circulated around the repeatedly under apredetermined pressure. In particular, the predetermined pressure isadjustable for regulating heat transfer efficiency.

The pressurized gas loop can comprise a pressure-to-motion device foroutputting mechanical movement, electricity or both. Thepressure-to-motion device converts pressure difference between its inletand outlet to mechanical motion, such as linear translation or rotarymovement. For example, the pressure-to-motion device is a piston engine(i.e. reciprocating engine) that converts the pressure difference into arotating motion. Alternatively, the pressure-to-motion device is aturbine or its variations for providing rotary motion of high speed(e.g. at 1,000 rpm).

The pressurized gas loop can further comprise a compressor forincreasing pressure of the refrigerant. For example, the refrigerant isconverted from gas to liquid phase by the elevation of pressure.Temperature change can also occur after the pressure or phase change.Since the heat exchanger on the shell can operate as anevaporator/boiler, the compressor and the heat exchanger can worktogether for extracting heat from the reactor via the phase change ofthe refrigerant, which is effective and efficient.

The pressurized gas loop can further comprise a heating portion forheating the refrigerant before entering the pressure-to-motion device.For example the heating portion can be exposed to flame of the syntheticgas for raising temperature of the refrigerant at a downstream of thepressurized gas loop. Pressure of refrigerant is further increased forpropelling the pressure-to-motion device faster.

The gasification device may further comprise a hydrogen gas circulationloop for receiving, collecting and converting the hydrogen gas to heat,water, or both. The hydrogen gas is a part of the synthetic gas, whichcomes from the reactor. The hydrogen gas loop may also transport othertypes of synthetic gas, such as carbon monoxide gas (CO). The hydrogengas loop takes exhaust gas of the reactor for heating the refrigerantsuch that the pressure-to-motion device can generate more energy, suchas electricity. In an alternative, the hydrogen gas may be collected forpowering a hydrogen fuel cell or for other industrial use.

The hydrogen gas circulation loop may comprise a gas separator (e.g.scrubber) connecting to the reactor for separating the hydrogen gas fromthe synthetic gas. For example, in a scrubber, a mixture of hydrogen gas(H₂) and carbon dioxide gas (CO₂) may be separated by pressurizing themixture at 5.2 Bar such that the carbon dioxide (CO₂) becomes liquid fordraining away from the hydrogen gas (H₂).

The hydrogen gas circulation loop may further comprise a hydrogen torchwhich is connected to a hydrogen upstream tube on the gas separator forheating a heating portion of the pressurized gas loop. The hydrogentorch can also burn the synthetic gas of other types, such as carbonmonoxide gas. Both the hydrogen torch and the heating portion may beenclosed or surrounded by a case or enclosure for avoiding leakage ofthe synthetic gas.

The hydrogen gas circulation loop can further comprise a liquid pumpconnected to a hydrogen burning chamber of the hydrogen gas circulationloop for circulating water to the water tank. The liquid pump canaccelerate the water circulation and/or propel the water to a highlevel. Hence the components of the gasification device can be moreflexibly arranged vertically for providing a compact apparatus.

The present application also provides an engine for providingelectricity or propulsion. The engine comprises the gasification deviceand an electricity converter connected to the pressure-to-motion device,the power supply, or both. The pressure-to-motion device of thegasification device provides mechanical driving force (e.g. torque) bydisassociating the hydrocarbon material into the synthetic gas. Thesynthetic gas may also be supplied as a fuel, either for pressurizingthe working fluid of the pressurized gas loop, or for causing pistonmotion in an Internal Combustion Engine (ICE). The engine can either beinstalled in a building for supplying electricity to a household, onboard for driving a vehicle.

The present application moreover provides a powertrain for providinglocomotion to a vehicle. The powertrain comprises the engine and atransmission connected to the engine. The transmission includes agearbox, a belt transmission, a chain drive or a combination of any ofthese. The powertrain delivers motions of related speed and amount towheels or propellers of the vehicle. The powertrain may alternativelydrive an electricity generator for charging an onboard battery of anelectric vehicle.

In the application, the heat exchanger may comprise a filtration systemfor removing impurities from the pressurized gas loop, which isbeneficial for maintaining the pressurized gas loop. Particular, theheat exchanger may comprise a condenser that can covert the workingfluid from gas phase to liquid phase. Hence, the working fluid can berepeatedly converted between the gas phase and the liquid phase insidethe pressurized gas loop for efficient heat transfer.

Another aspect of the present application provides a method forconverting or reforming a feedstock material (e.g. hydrocarbon material)into synthetic gas. The method comprises a first step of providing thefeedstock material to a burner inserted into a reactor, a second step ofsupplying ionized gasses into the reactor, and a third step ofsubjecting the burner to a flame of the ionized gases such thatmolecules of the feedstock material are dissociated in forming thesynthetic gas, basic element or compound. The three steps of operationmay be coordinated by a regulator (e.g. industrial computer), whichadjusts temperature, flow rate and pressure, at various positionsautomatically and continuously. The method can be implemented by a largefactory or by a compact apparatus onboard a vehicle. The feedstockmaterial may be replaced by an organic mixture in liquid or gas phase.

The step of providing the feedstock material or mixture can comprise astep of pulverizing or grinding a feedstock material/mixture into powderor fluid form for feeding through channels inside the burner. Feedstockmaterial in powder form can be more effectively exposed to a hightemperature environment for speedy disassociation.

The step of providing the feedstock mixture or material may comprise astep of squeezing the feedstock material through the channels. Underpressure, the feedstock material can be uniformly injected into thereactor with a predetermined rate, which is useful for controlling therate of synthetic gas generation.

The step of supplying ionized gases can comprise a step of delivering adirect electric current through an ionic substance via an anode and acathode. In an electrolysis operation, the anode and cathode receivepositive and negative charges, whilst the rate of HHO gas generation canbe controlled by regulating the voltage, current and pattern of charge(e.g. pulsation) of the direct current. The step of supplying theionized gas may also be achieved by passing an electric current (e.g.direct current) through water, or water with an electrolyte.

The step of supplying ionized gases may further comprise step ofigniting the ionized gases for generating the flame above 600° C.,1,000° C. or 3,000° C. The ignition may be automatically provided by apiezoelectric lighter or a spark plug such that the disassociationprocess of the feedstock material can be initiated automatically.

The step of supplying ionized gases can further comprise step of causingthe flame to touch the burner for heating up the feedstock mixture. Theflame may enwrap the burner such that the burner can be raised to anextreme temperature (e.g. above 2,200° C.), or even higher. The burnermay rotate or move linearly such that different parts of the burner canbe sequentially touched by the flame, whilst localized heating isavoided for preventing melted down of the burner.

The step of providing the hydrocarbon or compound or singular or pluralelement material may comprise a step of propelling the material betweenneighboring teeth of an Archimedean screw feeder. A thread of theArchimedean screw feeder can propel the material under regulated speed,whilst cooling the burner. Whilst the material is gaseous, it may justflow by the narrow the gap of space to a lower pressure zone.

The step of subjecting the burner to the flame can comprise a step ofshifting a feeding sleeve of the Archimedean screw feeder under theflames. The shifting action may be carried out by an electric motorconnected via a gear transmission. The feeding sleeve can be movedduring the process of disassociating the compound material ortransferring heat to material that flows through.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures (Figs.) illustrate embodiments and serve toexplain principles of the disclosed embodiments. It is to be understood,however, that these figures are presented for purposes of illustrationonly, and not for defining limits of relevant applications.

FIG. 1 illustrates a diagram of a gasification device;

FIG. 2 illustrates a burner of the gasification device; and

FIG. 3 illustrates an alternative burner of the gasification device.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Exemplary, non-limiting embodiments of the present application will nowbe described with references to the above-mentioned figures.

FIGS. 1 and 2 provide an embodiment of the present invention. Inparticular, FIG. 1 illustrates the diagram of the gasification device20. The gasification device 20 comprises a reactor 22, an HHO gasgenerator 24, a hydrogen gas circulation loop 26, a pressurized gas loop28 and an organic feeder 30.

The reactor 22 further comprises a burner 32, a torch 34, a slagcollector 36 and a shell 38. The shell 38 forms an enclosed chamber 40which is hermetic. At a lateral side 42 of the reactor 22, the burner 32is placed above the torch 34 with close proximity such that flames 44 ofthe torch 34 can spread over an exterior surface 46 of the burner 32when in use. In a longitudinal direction, at a bottom side 48 of thereactor 22, the slag collector 36 has an inverted cone shape such that awider opening 50 of the slag collector 36 opens towards top, whilst anarrower opening 52 of the slag collector 36 points downwards. A sideopening 54 is connected to the wider opening 50 for discharging slag 56from the slag collector 36. On a top side 57 of the reactor 22, a gasdischarge opening 59 is connected to a valve (not shown), opposite tothe bottom side 48.

FIG. 2 illustrates the burner 32 of the gasification device 20. Theburner 32 has a cylindrical shape and is made of tungsten materialhaving a melting point of 3,422° C. In a longitudinal direction of theburner 32 (see cylindrical axis), there are parallel cylindrical tunnels58 evenly distributed over a cross-section of the burner 32. Thediameter of the burner 32 is about 10 millimeters (mm), whilst each ofthe cylindrical tunnels 58 has a diameter of 0.5 millimeters (mm). Thecylindrical tunnels 58 open at a front end 60 of the burner 32 insidethe reactor 22, and connect to the feedstock feeder 30 at a back end 62.The burner 32 is inserted into the reactor 22 on the shell 38.

Referring back to FIG. 1, in contrast to the torch 34, the burner 32 ofthe reactor 22 is connected to the feedstock feeder 30. The feedstockfeeder 30 has a slurry tank 88 filled with an organic mixture 90, afeeding tube 92, a feeding pump (not shown), a feeding valve 93 and aregulator 95. The feeding tube 92 joins a bottom side of the slurry tank88 to the back end 62 of the burner 32. The feedstock mixture 90contains green waste, food waste, paper waste, and biodegradableplastics that are in a liquid or semi-solid form (e.g. slurry). Thefeeding valve 93 is connected to the regulator 95 for controlling flowrates of the organic mixture 90. The regulator 95 is further connectedto a temperature sensor 97 on the reactor 22 for controlling reactionrates of the gasification device 20. Pressure sensors 101 on thepressurized gas loop 28 is further connected to the regulator 95 forprocess control and monitoring.

In the reactor 22, the torch 34 provides a heat and ignition source thatcan cause the organic mixture 90, which exits front end 60 of the burner32. The flame 44 of the torch 34 can raise temperature of the burner 32to be more than 2,200° C. such that it can catalyze/disassociate theorganic mixture 90 into synthetic gas (syngas) 91 and solid waste (slag)56. The synthetic gas 91 includes CO, H₂, CH, etc. The burner 32 is anelectrically conductive material especially those at high temperaturethat is raised to a high temperature under the flame 44 of the ionizedgas (oxyhydrogen gas or HHO gas). The burner 32 further providesconduits 58 for providing an energy source (fuel or feedstock) of thereactor 22. The shell 38 forms an enclosed chamber 40 such that heatfrom the burner 32 and the torch 34 is preserved and removed only by thecarbon dioxide fluid 116. The slag collector 36 collects solid waste atbottom. Excess liquid (e.g. water) of the reactor 22 can be dischargedvia the narrower opening 52 below.

According to FIG. 1, the HHO gas generator 24 comprises a Direct Current(DC) power supply 64, an anode 66, a cathode 68, a concealed water tank70 partially filled with a potassium hydroxide (KOH) solution 72, andtwo orifice 74, 76 and a liquid pump 84. The anode 66 and the cathode 68are connected to opposite ends of the DC power supply 64, and they 66,68 are partially immersed inside the potassium hydroxide solution 72.The potassium hydroxide solution 72 in a liquid form fills a lowerportion of the water tank 70, whilst an upper portion of the water tank70 is filled with HHO gas 78. The HHO gas 78 differs from a mixture ofoxygen and hydrogen gases by having hydrogen and oxygen gases chargedwith ions (i.e. ionized hydrogen and oxygen gases). A liquid orifice 74of the HHO gas generator 24 is covered by the potassium hydroxidesolution 72, whilst a gas orifice 76 of the HHO gas generator 24 isexposed above the potassium hydroxide solution 72, and is located on topof the liquid orifice 74. The gas orifice 76 is connected to the torch34 via a tube 82 and a non-return valve 83, whilst the liquid orifice 74is connected to the narrower opening 52 of the slag collector 36. Theliquid pump 84 is mounted on another tube 86 that connects the liquidorifice 74 and the narrower opening 52 of the reactor 22.

The hydrogen gas circulation loop 26 includes a gas separator 94, ahydrogen upstream tube 96, a hydrogen burning chamber 98 and a hydrogendownstream tube 100, which are sequentially connected. Moreover, aninlet 102 of the gas separator 94, which is located at a bottom side ofthe gas separator 94, is linked to the gas discharge opening 59. Theinlet 102, which is also an exhaust of the reactor 22, has a dischargingvalve 103 for controlling gas flow rates between the reactor 22 and thegas separator 94. The hydrogen downstream tube 100 is further connectedto the narrower opening 52. A hydrogen torch 104 is interconnected to anexit 106 of the hydrogen upstream tube 96 and inserted into the hydrogenburning chamber 98. The gas separator 94 further has a vent 108 on itstop side and is connected to an interior of the gas separator 94.

In the hydrogen gas circulation loop 26, the gas separator 94 separatesthe synthetic gas 91 from the reactor 22 such that hydrogen gas 99 isdiverted into the hydrogen upstream tube 96, whilst remaining gases aredischarged via the vent 108 for further processing. The hydrogen torch104 can incinerate the hydrogen gas 99 for generating heat. The oxygengas is provided from ambient automatically.

The pressurized gas loop 28 has a copper pipe 110, a turbine 112 with apressure regulator 113 and a compressor 114 connected in series. Carbondioxide fluid 116 fills all of these three components 110, 112, 113,114. The copper pipe 110 has a reactor portion 118 and a heating portion120 serially connected to the turbine 112. In particular, the reactorportion 118 is inserted into the reactor 22 hermetically and exposedinside the chamber 40. The heating portion 120 penetrates through thehydrogen burning chamber 98 air tightly. Both the reactor portion 118and the heating portion 120 have radial fins (not shown) on theirexternal surfaces for facilitating heat exchange.

In the pressurized gas loop 28, the turbine 112 serves apressure-to-movement device that can receive the carbon dioxide fluid116 of higher pressure at its inlet 122 to rotary motion and dischargethe carbon dioxide fluid 116 of lower pressure at its outlet 124. Incontrast, the compressor 114 propels and pressurizes the carbon dioxidefluid 116 that leaves the turbine 112. In other words, the compressor114 can convert the carbon dioxide fluid 116 from gas phase to liquidphase. In contrast, the carbon dioxide of liquid phase can be convertedfrom liquid phase to gas phase after passing through the reactor portion118.

When in use, the DC power supply 64 discharges electric current to thepotassium hydroxide solution 72 via both the anode 66 and the cathode68. Electrically charged hydrogen and oxygen gases 78 (HHO gas) formbubbles on surfaces the electrodes 66, 68. The HHO gas 78 has ions 80and is highly inflammable. Since the HHO gas generator 24 ishermetically concealed, the HHO gas 78 leaves the HHO gas 78 via the gasorifice 76 and enters the torch 34. The HHO gas 78 is ignited by a piezoigniter element (not shown) at an outlet of the torch 34 such that theflame 44 wraps around and touches the burner 32 substantially. The piezoigniter element may be replaced by a spark plug.

The burner 32 is raised to be more than 2,200° C. under the flame 44. Inthe meantime, the organic mixture 90 in the slurry form is propelled bya pump (not shown) from the slurry tank 88 to the burner 32 via the backend 62. The organic mixture 90 cools the burner 32 when passing throughthe cylindrical tunnels 58. At the front end 30, the organic mixture 90is disassociated into constituent elements such that the organic mixture90 is converted into the synthetic gas 91 and the slag 56. The slag 56is formed by inorganic materials, such as scrap metals and constructionwaste. In the reactor 22, the slag 56 is accumulated at the slagcollector 36 and discharged through side opening 54. In contrast, thesynthetic gas 91 departs from the reactor 22 and enters into the gasseparator 94.

In the gas separator 94, the synthetic gas 91 is separated such that thehydrogen gas 99 goes into the hydrogen upstream tube 96, whilst theremaining gases escape from the gas separator 94 from the vent 108. Theremaining gases (e.g. CO& CH) are collected by a boiler (not shown) forconverting into useful energy or motion.

The hydrogen gas 99 travels from the gas separator 94 to the hydrogentorch 104 via the hydrogen upstream tube 96. The hydrogen gas 99 isburnt at the hydrogen torch 104 for heating the fins (not shown) of thehydrogen upstream tube 96. As a result, the hydrogen gas 99 reacts withoxygen gas taken from the ambient and is converted into water 126 inliquid or vapor form. The water 126 is further condensed or cooled downby the ambient when moving through the hydrogen downstream tube 100. Thedischarged water 126 is driven either into the water tank 70, or out ofthe gasification device 20. Water 126, which is formed inside thechamber 40 is also propelled either into the water tank 70, or out ofthe gasification device 20.

In the process of forming the synthetic gas 91, the carbon dioxide fluid116 is circulated around the pressurized gas loop 28. In detail, thecarbon dioxide fluid 116 in a liquid form is heated up by theatmospheric ambient temperature before the check valve 111 prior toentering the chamber 40 and further heated in the chamber 40 of thereactor portion 118 and evaporated into a gas form. The carbon dioxide116 in the gas form moves out of the reactor portion 118 and is furtherheated by the hydrogen torch 104, with increase in pressure. The carbondioxide gas 116 of high pressure pushes blades/rotor (not shown) of theturbine 112 to rotate for generating electricity and/or mechanicalmotion. The pressure regulator 113 controls the carbon dioxide pressureto the turbine 112 for speed and power regulation. In automaticfunction, regulator 95 controls pressure regulator with other sensorsfeedback. An electricity converter 128 is connected to the turbine 112for receiving energy input and providing electricity for supplying theDC power supply 64. In the meantime, the turbine 112 can be connected toa gearbox (not shown) of a vehicle 130 for transportation.

In the gasification device 20, the turbine 112 can alternatively bereplaced by a piston pump when dealing with high pressure. The pistonpump can still provide mechanical motion for generating the electricityand a drivetrain of the vehicle. In the HHO gas generator 24, the DCpower supply 64 can either provide stable direct current discharge orpulsating direct current discharge for generating the HHO gas 78.potassium hydroxide solution 72 may be replaced by water free frompotassium hydroxide, such as tap water. The feedstock feeder 30 caninclude a grinder such that organic feedingstocks (e.g. municipal solidwaste, organic waste) may be pulverized for feeding through thecylindrical tunnels 58 smoothly. The gasification device 20 can alsoperform pyrolysis process for decomposing organic material at elevatedtemperatures without the participation of oxygen, such that thegasification device 20 may be alternatively known as a pyrolysis device.The gasification device 20 can also be used as a reformer for otherchemical process.

FIG. 3 provides another embodiment of the invention. FIG. 3 shows partsthat have reference numerals similar or identical to those of FIGS. 1and 2. Description of the corresponding parts is therefore incorporatedby reference.

In particular, FIG. 3 illustrates an alternative burner 140 of thegasification device 20. The alternative burner 140 has an Archimedeanscrew feeder 168 and a feedstock propeller 170 that are coupledtogether.

The Archimedean screw feeder 168 further comprises a feeding sleeve 142,a feeding screw 144, a screw holder 146, a wall bracket 148 and a wallbracket bearing 150. The feeding screw 144 is contiguously inserted intothe feeding sleeve 142, whilst the feeding sleeve 142 is snugly slottedinside an opening on the wall bracket 148. The feeding sleeve 142 iscylindrical and made of silicon carbide (SiC) material. The wall bracketbearing 150 is tightly held between the wall bracket 148 and the screwholder 146 such that the wall bracket 148 and the screw holder 146 canrotate with respect to each other around a rotary axis of the wallbracket bearing 150.

The feedstock propeller 170 further comprises a screw handle 152, ascrew bearing 154, a motor bracket 156, a screw joint 158, a feedingmotor 160, a (feeding) motor casing 161, a roll motor 162, a drivinggear 164 and a driven gear 166. The screw handle 152 is attached to anend of the feeding screw 144 and a shaft of the feeding motor 160. Thescrew bearing 154 is firmly seized between the motor bracket 156 and thescrew handle 152. Both the motor bracket 156 and the feeding motor 160are enclosed by and affixed to the motor casing 161. The roll motor 162is attached to the wall bracket 148. The roll motor 162 includes a motorshaft 163, which is inserted into the driving gear 164. In contrast, thedriven gear 166 is fixed onto the screw holder 146, whilst the drivinggear 164 meshes with the driven gear 166.

When in use, the organic mixture 90 is poured into a receptacle 147 ofthe screw holder 146. Since the feeding motor 160 causes the feedingscrew 144 to rotate via the screw joint 158 and the screw handle 152,the organic mixture 90 is squeezed by threads 149 of the feeding screw144 and moves forward towards a discharge opening 172 of the Archimedeanscrew feeder 168. In the meantime, the feeding sleeve 142 rotatescontinuously clockwise and anticlockwise (back and forth), whilst thefeeding sleeve 142 is rolled continuously by the roll motor 162. In afeeding process, the organic mixture 90 is propelled between neighboringteeth of the feeding screw 144 and ejected out of the discharge opening172. Since the flames 44 a, 44 b touch the feeding sleeve 142 and raiseits temperature to above 2,200° C., the organic mixture 90 is decomposedunder the high temperature in forming the synthetic gas 91 or reformedcompound in the reactor 22, which are basic forms of materials made offundamental constituent elements/molecules. Both the feeding motor 160and the roll motor 162 are connected to control unit (not shown) of thereactor 22 such that the rotation range and speed of these motors 160,162 are precisely regulated. When rotating, the wall bracket bearing 150and the screw bearing 154 provide stable support to parts of the burner140 for operation under high temperature. Rotary torque of the feedingsleeve 142 is provided from the roll motor 162, via the motor shaft 163,via the driving gear 164, via the driven gear 166, via the motor bracket156, to the feeding sleeve 142. In contrast, rotary torque of thefeeding screw 144 is transmitted from the feeding motor 160, via thescrew joint 158, via the screw handle 152, to the feeding screw 144.

In the alternative burner 140, the meshing between the gears 164, 166may be replaced by friction engagement between mechanical parts or achain drive. The silicon carbide may also be replaced by other materialsthat can withstand extreme high temperature.

In the application, unless specified otherwise, the terms “comprising”,“comprise”, and grammatical variants thereof, intended to represent“open” or “inclusive” language such that they include recited elementsbut also permit inclusion of additional, non-explicitly recitedelements.

As used herein, the term “about”, in the context of concentrations ofcomponents of the formulations, typically means +/−5% of the statedvalue, more typically +/−4% of the stated value, more typically +/−3% ofthe stated value, more typically, +/−2% of the stated value, even moretypically +/−1% of the stated value, and even more typically +/−0.5% ofthe stated value.

Throughout this disclosure, certain embodiments may be disclosed in arange format. The description in range format is merely for convenienceand brevity and should not be construed as an inflexible limitation onthe scope of the disclosed ranges. Accordingly, the description of arange should be considered to have specifically disclosed all thepossible sub-ranges as well as individual numerical values within thatrange. For example, description of a range such as from 1 to 6 should beconsidered to have specifically disclosed sub-ranges such as from 1 to3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc.,as well as individual numbers within that range, for example, 1, 2, 3,4, 5, and 6. This applies regardless of the breadth of the range.

It will be apparent that various other modifications and adaptations ofthe application will be apparent to the person skilled in the art afterreading the foregoing disclosure without departing from the spirit andscope of the application and it is intended that all such modificationsand adaptations come within the scope of the appended claims.

What is claimed is:
 1. A gasification device, comprising: a reactor fordisassociating a feedstock material into at least two gases, the reactorincluding a heating device for discharging an ionized gas into thereactor; a gas generator connected to the heating device forgasification, the gas generator comprising a water tank, the water tankcomprising a liquid orifice for receiving a water in a liquid or a gasform, and a gas orifice for releasing an ionized gas; a hydrogen gascirculation loop for receiving, collecting and or converting the atleast one gas into heat, water, or both, with the hydrogen gascirculation loop comprising a gas separator connected to the reactor forseparating the at least two gases; and a pressurized gas loop that isconnected to the reactor for absorbing heat from the reactor.
 2. Thegasification device of claim 1, wherein the pressurized gas loopcomprises a pressure-to-motion device, a pressure regulator or both foroutputting a mechanical movement, an electric current, or both.
 3. Thegasification device of claim 1, wherein the pressurized gas loop furthercomprises a compressor for increasing a pressure of a refrigerant. 4.The gasification device of claim 3, wherein the refrigerant comprises acarbon dioxide fluid.
 5. The gasification device of claim 3, wherein thepressurized gas loop further comprises a heating portion for heating therefrigerant before entering the pressure-to-motion device.
 6. An enginefor providing an electric current or a propulsive force, the enginecomprising: a reactor for disassociating a feedstock material into atleast two gases, the reactor including a heating device for dischargingan ionized gas into the reactor; a gas generator connected to theheating device for gasification, the gas generator comprising a watertank, the water tank comprising a liquid orifice for receiving a waterin a liquid or a gas form, and a gas orifice for releasing an ionizedgas; a hydrogen gas circulation loop for receiving, collecting and orconverting the at least one gas into heat, water, or both, with thehydrogen gas circulation loop comprising a gas separator connected tothe reactor for separating the at least two gases; and a pressurized gasloop that is connected to the reactor for absorbing heat from thereactor, the pressurized gas loop comprising a pressure-to-motiondevice, a pressure regulator or both for outputting a mechanicalmovement, an electric current, or both.
 7. A powertrain for providing alocomotion to a vehicle, the powertrain comprising: a reactor fordisassociating a feedstock material into at least two gases, the reactorincluding a heating device for discharging an ionized gas into thereactor; a gas generator connected to the heating device forgasification, the gas generator comprising a water tank, the water tankcomprising a liquid orifice for receiving a water in a liquid or a gasform, and a gas orifice for releasing an ionized gas; a hydrogen gascirculation loop for receiving, collecting and or converting the atleast one gas into heat, water, or both, with the hydrogen gascirculation loop comprising a gas separator connected to the reactor forseparating the at least two gases; a pressurized gas loop that isconnected to the reactor for absorbing heat from the reactor, thepressurized gas loop comprising a pressure-to-motion device, a pressureregulator or both for outputting a mechanical movement, an electriccurrent, or both; and a transmission connected to the pressure-to-motiondevice.